HYBRID / BATTERY CONTROL: HYBRID BATTERY SYSTEM (for LITHIUM-ION BATTERY): PRECAUTION; 2020 - 2024 MY RAV4 HV [06/2020

(a) Before the following operations are conducted, take precautions to prevent electric shock by turning the ignition switch off, wearing insulated gloves, and removing the service plug grip from HV battery.

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
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After removing the service plug grip, turning the ignition switch to ON (READY) may cause a malfunction. Do not turn the ignition switch to ON (READY) unless instructed by the repair manual.

(b) To prevent electric shock, make sure to remove the service plug grip to cut off the high voltage circuit before servicing the vehicle.

(c) After removing the service plug grip, put it in your pocket to prevent other technicians from accidentally reconnecting it while you are working on the high-voltage system.

(d) After removing the service plug grip, wait for at least 10 minutes before touching any of the high-voltage connectors or terminals.

Waiting for at least 10 minutes is required to discharge the high-voltage capacitor inside the inverter with converter assembly.

(e) Check the voltage at the terminals in the inspection point in the inverter with converter assembly.

(1) Remove the connector cover assembly from the inverter with converter assembly.

(f) When turning the ignition switch to ON during an inspection, do not press the ignition switch with the brake pedal depressed.

Pressing the ignition switch with the brake pedal depressed causes the system to enter the READY-on state. This is very dangerous because high voltage may be applied to the inspection area.

(g) Turn the ignition switch off, wear insulated gloves, and disconnect the cable from the negative (-) terminal of the auxiliary battery before touching any of the orange-colored wires of the high-voltage system.

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.

(i) Turn the ignition switch off before disconnecting or reconnecting any connectors.

(j) When performing work involving high-voltage wires, use either a tool wrapped with vinyl insulation tape or an insulated tool.

(k) When high-voltage connectors are removed, wrap the connectors with insulation tape to prevent them from contacting foreign matter.

(a) When the warning is illuminated, or the auxiliary battery has been disconnected and reconnected, attempting to turn the ignition switch to ON (READY) may not start the system (the system may not enter the READY-on state) on the first attempt. If so, turn the ignition switch off and reattempt to start the hybrid system.

The AMD terminal is connected to the positive terminal of the auxiliary battery. To prevent damage when the AMD terminal is being disconnected, use the following procedure.

(a) Be sure to disconnect the cable from the negative (-) auxiliary battery terminal before disconnecting the AMD terminal from the No. 1 engine room relay block and junction block assembly.

(b) After disconnecting the AMD terminal, wrap the terminal with insulation tape.

(c) Be sure to reconnect the AMD terminal to the No. 1 engine room relay block and junction block assembly before reconnecting the cable to the negative (-) terminal of the auxiliary battery.

A short circuit to ground may occur if the AMD terminal is disconnected before the cable is disconnected from the negative (-) terminal of the auxiliary battery. If a short circuit to ground occurs, it can result in an open circuit in a fusible link or fuse.

(a) When disposing of HV batteries and HV supply stack sub-assemblies, make sure to return them through an authorized collection agent who is capable of handling them safely. If they are returned via the manufacturer specified route, they will be returned properly and in a safe manner by an authorized collection agent.

CAUTION:

After removing the HV battery, keep it away from water. Exposure to water may cause the HV battery to produce heat, resulting in a fire.

Accidents such as electric shock may result if the HV battery is disposed of improperly or abandoned.

Therefore, make sure to return HV battery through an authorized collection agent.

*a	Dealer
*b	Battery Collection Agent

To reduce the risk of fire, HV battery must not be stored in an area where they will be exposed to fire or high temperatures.
If the temperature of the HV battery is high, leave the vehicle until the temperature drops.
Make sure to insulate the high-voltage connectors and terminals of the HV battery with insulating tape after removing it.
If the HV battery stored without insulating the connectors and terminals, electric shock or fire may result.
Before returning the HV battery, make sure to perform a recovery inspection.
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Before returning the HV supply stack sub-assembly, make sure to perform a recovery inspection
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HV battery learning values are stored in the battery ECU assembly and ECM to display "HAVE TRACTION BATTERY INSPECTED" on the multi-information display. When either of these ECUs is replaced, the new ECU receives the HV battery learning value data from the other ECU and updates the information.

NOTICE:

Do not replace the battery ECU assembly and ECM at the same time as it clears the HV battery learning values. However, if it is necessary to replace both ECUs at the same time, replace them by following the procedure below.
Do not replace the battery ECU assembly or ECM with used ones from other vehicles.

(5) Turn the ignition switch off and disconnect the cable from the negative (-) auxiliary battery terminal.

If the battery ECU assembly and ECM are replaced at the same time without following the above procedure, replace either of the ECUs with its original one and then replace it again by following the above procedure. If the correct procedure is not followed, perform the procedure again from the beginning.

(a) Before performing work on electronic components, disconnect the cable from the negative (-) auxiliary battery terminal to prevent damage to the electrical system or electrical components.

(b) Before disconnecting and reconnecting the auxiliary battery cable, turn the ignition switch off and the headlight switch off. Then loosen the terminal nut completely. Do not damage the cable or terminal.

(c) When the auxiliary battery cable is disconnected, the clock and radio settings and stored DTCs are cleared. Therefore, before disconnecting the auxiliary battery cable, make a note of them.

NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) auxiliary battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) auxiliary battery terminal notices before proceeding with work.
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When the cable is disconnected from the negative (-) auxiliary battery terminal, initialize the following systems after the cable is reconnected.